Wall structure and building block therefor



April 2, 1.940- G. D. KING 2,196,074

` WALL STRUCTURE AND BUILDING BLCCK THEREFOR Filed' Feb, 2a, lase' Patented Apr. 2, 19140v AUNITED STATES WALL sTaUc'rUna AND BUILDING BLOCK' l marron George D. King, Chicago, Ill assigner to United States Gypsum (kmpany, Chicago, lll., a corporation of Illinois Application February 28, 1938, Serial No. 192,929'

17 Claim..

'I'his invention relates to cellular wall structure and building block therefor, and more particularly toa light-transmitting wall comprising a. cellular frame-like load-supporting portion having closely adjacent individual transverse cells therethrough with comparatively thin partitions therebetween and light-transmitting facings covering the `open sides of the frame or shell whereby each cell provides alcomparatively small lo individual dead air space to provide effective heat insulation and to enable light transmission wmpletely through the wall.

It is an object of the invention to provide a.`

wall. of the character described in which the component parts are so lconstructed. and arranged 'as to enable only restricted so-called breathing of individual cells through one side of the wall While preventing breathing and the innltratlon of'moisture or water vapor through 120 the opposite side of the wall and preferably also preventing moisture iniiltr'ation between cells.

Wherever the .term "breathing is used in the specication or claims as descriptive of a char--4 acterlstic of the invention disclosed herein, it is V intended to mean that only restricted breathing n may take place, such breathing being only sufficient to enable the maintenance of a moisture content within the block substantially corresponding to the moisture content of the air on the outside oi the wall. yThis is accomplished by diii'usionv and infiltration which is not suiiicient to permit rapid changes of air such as ordinarily termed Aconvection currents.

The invention further contemplates alighttransmitting -wall structure. comprising individual units or blocks preferably secured together 'with mortar and each having one or more hollow spaces or cells therein throughv which light may be transmitted, and which are -so constructed M and arranged'that one sideofthe wall may be substantially impervious to moisture and-water vapor and the oppositeside will enable breathing of the hollow space in each individual unit.

The invention is particularly applicable to load-supporting blocks and walls" constructed thereof however, it is not'lmited thereto, as it is applicable to other types of ,hollow blocks,

such, for instance, as all-glass'ublocks having (Cl. i2-42) l anpervious to air, moisturefand water vapor and in which the open sidesV of the shell are closed by means of light-transmitting plates or so-ealled facings. The facing on one side of each shell is sealed thereto in a manner to previl vent breathing from one side of awall in which the blocks are used, and the facing 'on the opposite side of the shell isso constructed or so attached that so-called breathing may take place. The ports or holes in the facing of the l0 shell through which the breathing takes place may be so constructedl thatl air and moisture vapor may passv into and out of the shell without material convection currents being set up, as will be hereinafter more specificallyl described.'Av

In practiceit has been foundthat in cold yweather any moisture present in the hollow I space within a light-transmitting building block will have a tendency to condense on the interior surface of the cover plate or facing adjacent 20' the cold side of the wall and may even form a frost coating. 'I'his is true even'with all-glass blocks which are-sealed underVa-f'vafc'zuuzrr; or at least under less than -atmosphericf-pressure. This condensation decreases light transmission, 25 gives an unclean appearance A'to the block, and creates the impression to an observer that the block is defective.

The present invention contemplates a loadbearing. and light-transmitting block wherein $0 oneside of the block may permit breathing therethrough in such a manner that condensation on the inside of the exposed face is materially decreased or entirely eliminated.

It is afurther object to provide a wall struc-fv as ture k comprising a plurality of superlmim'sed. hollow blocks havingl light-transmitting facings wherein the wall and the componentparts are' L arranged to enable moisture diffusion from the hollow space in each block through the vouter 40 surface of said wall without. permitting heat loss by convection currents to an appreciable extent. Tlie heat-insulating value of the so-called "dead air" space is, thereioreUnot materially decreased, Q

This invention is an improvement over the usual type of hollow building blocks whichv may or may not be light-transmitting, and particularly is .an improvement over light-transmitting blocks of the typedisclosed in the copending ap- 5o plication of George D. King and` George L. Phelps, Serial No. 185,825, filed January 20, 1938.

In the above-noted application a building block is provided which comprises a hollow shell formed of plastic material' such as gypsum or u other4 suitable cement or aggregate. Otherl suitable materials may be used, such as Portland cement, terra cotta, burned clay, metal, processed wood, or other material which may be b cast or otherwise `formed into hollow shells by the usual well known methods. These hollow shells are preferably pressure molded and may be provided with moisture` and moisture-vapor proof characteristics either by incorporating waterproofing material with the base material from which the shells are formed or by suitably coating or impregnating the shell in such a manner that substantially the entire surface is moisture and water-vapor proof. Light-transmitting plates or facings, such as glass or other suitable material, are sealed to the side walls of the shell in amanner to close the openings therein and to enable relative contraction and expansion of4 the component parts without destroying the cffectlveness of thel seal. vThe light-transmitting plates are inherently impervious to air and moisture in any form. Therefore, the completed hollow block is effectively sealed against air and moisture or Water-vapor infiltration. It has been found, however, that in blocks of this type some condensation may take place on the inner l surface of the outside facing. It is, therefore, an object of the present invention to provide means whereby this condensation may be substantially eliminated and the light-transmitting characteristics of the block will be unimpaired and a wall constructed of such lblocks will enable light to be transmitted completely therethrough.

Further objects will be apparent from the specification and the appended claims.V

In the drawing:

Figure 1 is a perspective view of arectangular block partly broken away and illustrates one em- Q bodiment of the invention.

' Fig. 2 is a perspective view of a block somewhat similar to that shown in Fig. 1, but elongated and provided with a transverse partition for the purpose of providing greater load-bearing strength.

Fig. 3 is a transverse sectional view taken on a line substantially corresponding to line 3--3 of Fig. 2 and illustrates one method of securing the side plates and providing breathing characteristics. Fg. 4 is a diagrammatic view illustrating the blocks in position in a wall with the usual mortar therebetween.

Fig.` 5 is a fragmentary sectional view similar 55- to Fig. 3 but illustrates a slightly different means to enable breathing through the outer surface'of the-wall. Fig. 6 is a front view of the embodiment illustrated in Fig. 5.

Fig. 'I is a transverse sectional view similar -to Fig. 3, but illustrates a slightly different method of securing the front light-transmitting plate whereby breathing is permitted.

Fig. 8 is a fragmentary view illustrating an- 65 other method of mounting the plates and providing for breathing.

Fig. 9 is a. perspective view of an all-glass block with a portion broken away and illustrates one embodiment of .the invention.

70 Fig. 10 is anenlarged detail section through the light-transmitting portion of a block and illustrates a method of providing a filter in aJ breather opening.

Referring to the drawing in detail, the em- 75 bodiment illustrated in Figs. 1 and 4 comprises a rectangular hollow shell I having comparatively thick walls and open sides as illustrated, the rear open side being covered by means of a light-transmitting plate or facing 2 which may be of glass or other suitable material and the front side being covered by means of a similar light-transmitting facing 3. By this construction itwill be apparent that light may be transmitted completely through the block and therefore through a wall in which the blocks are incorporated.

The shell I is preferably pressure molded or otherwise formed of gypsum or a suitable cement or aggregate. Other suitable materials may be used to provide the necessary strength and may be such as to provide suitable moisture-proof characteristics, or the shells may be entirely coated with suitable moisture and water-vapor proofing material. In any event, the shell is of suitable material and so constructed as to provide a unit capable of supporting a substantial load and preferably capable of bonding with conventional mortars. An eiiicient reinforcing means, such as expanded metal 4, may be embedded within the material of the block as illustrated in Fig. 3.

In cases where the material of the block is not inherently moisture and water-vapor proof, the entire inner and outer surfaces of the shell may be coatedwith suitable waterproofing material to prevent moisture or vapor infiltration. The light-transmitting acings 3 may be secured in position by a layer of suitable adhesive material 5 (Figs. l and 2) applied between the facings and the walls of the shell. This adhesive 5 is preferably a yieldable material such as an asphaltadhesive and therefore permits a differential contraction and expansion of -the shell and facings in response to temperature changes.

The shell may be formed with an annular.

groove or depression 6 therein, as shown particularly in Figs. l and 4, which provides-a pocket between adjacent blocks in a wall. This pocket may be completely filled with mortar l (Fig. 4). When this groove or pocket is used, the outer edges of the block may be substantially in contact as shown and the visible mortar joint between the facings is thereby reduced to a minimum.

The facings 2 and' 3 are somewhat smaller than the sides of the block so that substantially the entire load is supported by the shells. 'Ihe walls of the block are preferably somewhat thinner adjacent the edges than in the middle (Fig. 4), thereby reducing to a minimum theV non-lighttransmitting areas of the block.

'I'he outer surface of the shell may be provided,v

with a moisture and vapor proof coating l (Fig. 3) and the facings may be secured and sealed to the walls by means of a layer of ilexible adhesive Q therebetween. This adhesive may be of 4material similar to the coating I or any other suitable flexible material such as adhesive I, whereby relative expansion and contraction may take place without injury to the blocks and whereby the shell will not be broken. It will be understood, of course.' that the embodiment shown in Fig. 2 may also be provided with an annular groove similar to the SI'OGVe 6 if desired. In this embodiment the elongated block I'L may be provided with one or more transverse partitions I0, which provide air cells of a predetermined size and contribute additional loadsupporting strength.

As previously stated, the facings and the shell 50 substantially undisturbed, even though perforaentering therein. It will be understood that it are impervious moisture and water vapor, if desired, this washer may be corrugated, air

particularlyafter' the block has been completely assembled, andthe rear facing is'so attached to the shellV that lmoisture or water vapor cannot infiltrate intothe hollow` block through the shell or the rear ,facing or therebetween.-

In thev present invention, the front facing 3 may also -be completely sealed to lthe 'block as described. However, means is provided whereby so-called breathing may t'ake place on that side of the block normally exposed to low tem- `.peratura building structure the breathing side should face a live air space `or a space tofwhich a large volurne of air is permitted to flow.

In theembodimentillustrated in Figs. 1 to 4, inclusive, a plurality of small perforations or slits When the Jblocks are 'assembled in ay porous, or otherwise formed to provide a breathlng outlet.

Fig. 8 illustrates another embodiment in which the shell I is covered with a sheet metal covering I9. This covering extends outwardly beyond ing or pressing an outer flange or lug 2| from Y the" dotted line position to the position against Il are provided through the facing 3, one or morevof the-perforations preferably being positioned adjacent' the bottom -of the block, as shown, and one or lmore similar perforations IIal being positioned adjacent the top of the block and communicating withthe hollow space therein. The perforationsy are preferably angularly disposed, as illustrated, in order to prevent water is not essential that the perforations should be in the positions shown nor that they should be angularly disposed. In any event, a suicient.

number of perforations are provided and so distributed as to provide for sc -called breathing through the front facing 3. The perforations are very small, .preferably about one-sixteenth inch in diameter, and so disposed through the facing as to enable the diifusio'n of moisture therethroughy without the formation of convection currents suiiicient to materially reduce the insulating characteristicsy of the so-called dead air space within the block. In other words, the

lperforations are so formed and 'arranged and are of such number as to maintain by diffusion the glass, as shown. The sheet metal member Fig. 10 is an enlarged sectional view through 25 vone of the breather openings and illustrates a method of providing aporous filter in the wall of a block which filter will enable moisture-diffusion through one surface of a wall and effectively prevent .convection currents. 'I'he filters 80 may, of course, be placed in suitable locations to enable breathing of the individual blocks or throughtheouter surface of the wall as .previously described. v

In the embodiment illustrated, a suitable open- 85 ing 23 may be provided through one of the light transparent facings 3 and this opening maybe of any suitable size and shape as required. A breathing filter 24 may be inserted in the opening 23 yand may consist of any suitable filtering 4o substantially the` same moisture concentrationwithin the hollow space as on the outside. For

ration one-sixteenth inch in diameter placed near eachv corner will generally be sufficient instance, in a block ten inches square, a perfo-- "I'he moisture consequently diffuses in and out tions1 are present, andthe insulatingl value of V the airv Spac'eis` substantially unimpaired.

In the embodiment illustrated inFigs. `5 and 6, the facing isA not perforated.

Instead, a small an'gular'sheet metal member I2 is provided and 4 insertedK between lthe facing and the block, as shown, and is retainedv inposition by means of the adhesive bywhich the facing is secured. The

member I2 is' formed to provide a very small duct I3 betweenfihe facing and the block, and these members' 'I'.rnay'be distributed around the edges of `thefacirig as desired. It will be apparent that, in thi/Se'mbOdiment, breathing may take place inthesame manner as previously described. I

Fig.7 Yillustrates another method by which 'y 4breathing may be accomplished.- -In this embodiment the facings are provided with openings I4 `to'receiverscrews I5, by which the facings may be secured tothe shells. Sockets I8 may be embedded inthe' shellsA to receive the screws.v

In this embodiment the edges of the shells may.

material such asa porous ceramic body which may be fused into place as shown `or the porous body may be adhesively or otherwise suitably secured. These filter portions may be distributed in accordance with ltering requirements, and it will -be understood, of course, that the openings II may be` closed by-similar filtering plugs if desired. These filters may. comprise slnteredglass,

unglazed porcelain, or similar porous material which will enable so-called breathingand mois- A vture diifusion therethrough and at the same time forefdesiredthat the invention bei limited only by the prior art and the scope' of theappended claims. l v

' Having thus described this invention, what is claimed and desired to be secured by Letters Patent is: 1 65 vl. A light-transmittingwall structure comv"p rising ycellular frame-like load-supporting portion having closely adjacentI transverse cells' therethrough Withcomparatively thin partitions therebetween, and light-transmitting facings closing. the open ends of said cells, said frame and one side of said wall being substantially moisture and water-vapor proof, the` opposite side of said wall being moisturep'ermeable. suiflciently to enable diffusion therethrough whilef substan-'75 tially preventing convection currents sufficient to materially reduce the heat insulating characteristics of the air spaces.

2. A light-transmitting wall structure Icomprising a cellular frame-like load-supporting portion having closely adjacent transverse cells therethrough with comparatively thin partitions therebetween, and light-transmitting facings closing the open ends of said cells in non-loadbearing relation to each other and to said loadbearing portion, means sealing the facings to said load-bearing portion in a manner to prevent moisture or water-'vapor infiltration therebetween, the facings on one side of said wall being moisture permeable only sufficiently to enable diiusion therethrough Without material convection.

3. A light-transmitting wall structure comprising a cellular frame-like load-supporting portion having closely adjacent transverse cells therethrough with comparatively thin partitions therebetween, and light-transmitting facings closing the open ends of said cells in non-loadbearing relation to each other and to said loadbearing portion, means sealing the facings to said load-bearing portion in a manner to prevent moisture or water-vapor infiltration therebetween, said sealing means being sufiicientlyvfiexible to enable relative expansion and contraction therebetween in response to temperature changes, the facings on one side of said wall being moisture permeable only `suiiiciently to enable diffusion therethrough without material convection.

4. In a light-transmitting wall structure, a cellular load support comprising comparatively thin vertical and horizontal intersectingpartitions forming closely adjacent cells, light-transbreathing of the hollow spaces without excessive mitting facings covering the open ends of said cells in non-load-bearing relation to said loadsupporting portion and to each other, the facings on one side of said wall being sealed to said support and forming therewith a substantial barrier against the infiltration of moisture or water vapor through said wall, wall being permeable by moisture and substantially preventing convection currents.

5. A wall structure comprising a'plurality of superimposed hollow blocks having light-transmitting facings, the outer sides of saidblocks having perforations of appropriate size to enablebreathing of the hollowspace therein and substantially prevent convection.

6. A wall structure comprising a plurality of superimposed hollow blocks having light-transmitti'ng facings, the outer facings of said blocks having perforations of appropriate size toA enable convection, seid perforations being angularly disposed to prevent flow oi' liquid moisture into said hollow spaces.

7. A light-transmitting wall structure `for heated buildings comprising wall-forming hollow building blockshaving light-transmitting sides, means securing said blocks together to form a substantially non-air-porous wall, the outer sides of said blocks being air porous.

8. -In a building block, the combination with a load-supporting hollowv shell having at least one open side, all of said shell, including one closed side, being sealed. against the inltration of air and moisture therethrough, with means closing the opposite side, said means having structural characteristics enabling moisture to be diffused therethrough and substantially preventing convection.

the opposite side of said 9. In a building block having a dead air space, the combination with a hollow load-supporting shell having open sides and comprising plastic.

material impervious to air and moisture and moisture vapor, of a light-transmitting facing sealed to' one side of said shell to prevent air and moisture inflltration to the hollow space, and a light-transmitting facing secured to the opposite side, said last facing having small perforations therethrough of sufiicient size to enable diffusion therethrough withoutA the formation of convection currents sufficient to materially re duce the heat insulating characteristics of said dead air space.

10. In a load-bearing, light-transmitting block, the combination with an air and moisture impervious shell having open sides of light-transmitting plates sealing said open sides, one side of said block being provided with passageways sufiiciently small to enable air and moisture infiltration therethrough while preventing convection.

11. A hollow building block of moisture impermeable material and having light-transmitting faces covering the hollow space, one side only of said block having ducts leading from said hollow infiltration therethrough, an'd a. light-transmitting facing secured to the opposite side of said shell, said facings being supported in non-loadbearing relation to said shell, the last mentioned side of said block being provided with one or more perforations therethrough of a size to enable breathingwithout material convection currents.

13. A hollow building block comprising a moisture proof shell having open sides, a moisture proof light-transmitting facing attached to each open side, a moisture proof seal between said moisture proof facing and said shell, and means providing an air duct -from the hollow space in said block and between said block and said fac- 14. A hollow building block comprising a substantially moisture proof shell having open sides, and a moisture proof light-transmitting closure covering each open side, a restricted portion of the closure on one side comprising a cellular ma.- terial having the filtering characteristics of unglazed porcelain or the like.

15. A hollow building block having light-transmitting sides, and one or more restrictedareas of one side comprising porous filtering material having filtering characteristics comparable to unglazed porcelain or the like whereby moisture or moisture vapor may pass therethrough while substantially preventing detrimental convection currents.

16. A hollow building block comprising a shell oi'v non-porous material, one side only of said blockhaving spaced restricted areas of porous material having the filtering characteristics of sintered glass or the like. Y

17. A =wall structure comprising a plurality of superimposed hollow blocks having light-transmittingv facings, one of said facings being substantially impervious to air and moisture, the other facing having portions sufilciently porous to enable moisture infiltration and diliusion therethrough while preventing material convection.

' GEORGE D. KING. 

